Method for making an expansible corrugated paperboard carton



July 12, 1966 F. L. YOUNG 3,260,172

METHOD FOR MAKING AN EXPANSIBLE CORRUGATED PAPERBOARD CARTON Original Filed Aug. 5, 1963 fig 64 62 62 64 65 21 1 65 mm! "mm V 4 W m1 5352 FIG.2

INVENTOR.

FRANK L. YOUNG ATTORNEYS United States Patent 3,260,172 METHOD FOR MAKING AN EXPANSIBLE CORRU- GATED PAPERBOARD CARTON Frank L. Young, 1601 N. 72nd St., Philadelphia, Pa. Original application Aug. 5, 1963, Ser. No. 299,812, now

Patent No. 3,144,979, dated Aug. 18, 1964. Divided and this application Apr. 30, 1964, Ser. No. 367,918

1 Claim. (Cl. 9336) This application is a division of my parent application, Serial No. 299,812, filed August-.5, 1963, now Patent No. 3,144,979, issued August 18, .1964.

This invention relates to a method of making an expansible corrugated paperboard carton which is adapted to be fabricated from a single blank on continuous folding and gumming machines. More particularly, it relates to a flatly formed carton having folding lateral panels which are capable of being readily expanded or contracted to accommodate articles of various sizes while providing protection to fragile contents against shock or other damage at all times. The car-ton of the instant invention is especially suitable for shipping, mailing or storage of merchandise such as books, bottles and the like, and is easily convertible from a flat envelope configuration to a sturdy box-like container which will resiliently protect the enclosed article.

In the past, collapsible cartons were designed only to hold the contents when the container was fully erected in'the form of a box. While the cartons themselves could be shipped or stored in flat or knock-down cond tion, they were not capable in their folded state of receiving articles. That is, their construction was primarily intended for employment as a completely assembled shipping container, and they were not adapted in collapsed condition for use as a shipping medium.

Furthermore, the prior art cartons of a particular cubic dimension could not readily accommodate articles of various sizes and shapes. Where articles of much smaller dimension than that of the carton itself .were packed, stuffing with dunnage was required in order to prevent undue ;freedom of movement and rattling in transit.

It is therefore an object of this invention to provide a method for making a collapsible carton which has equal utility as a container in either flat-tolded, partially expanded, or fully expanded condition.

Another object of this invention is to provide a method for making a corrugated paperboard container which is capable of being stored fiat and thereafter used as a flatfolded envelope or which can be expanded into box-like configuration to receive articles of various sizes.

It is also an object of the invention to provide a methed for making a container wherein irregularly shaped objects, not completely filling the container, may be wedged into fixed position by a bottom element, when said element is partially expanded.

Another object of this invention is to provide a method for making a corrugated paperboard envelope having expansi-ble lateral panels which is adapted to offer protection against shock or other damage to fragile articles received therein.

An additional object of the invention is to provide a method for making an envelope having double edges on each side which afford additional protection for the contents when the envelope is partially expanded.

Another object of this invention is to provide a method for making an expansible corrugated paperboard carton which will resiliently embrace articles of various sizes and shapes so that articles having dimensions much smaller than the expanded carton can be retained in generally fixed position therein during shipment without requiring dunnage or stuffing.

3,260,172 Patented July 12, 1966 Still another object of this invention is to provide a method tor making an envelope-like, expansible, corrugated, paperboard carton which can be readily fabricated on continuous gumming and folding machines.

Yet another object of this invention is to provide a method for making a corrugated paperboard .container which is urged into expanded condition as the articles are inserted therein. 4

A still further object of this invention is to provide a method for making an expansible envelope fabricated from corrugated paperboard and having fully closed upper and lower corners.

Other objects of this invention are to provide an improved device and method of the character described that is easily and economically produced, which is sturdy in construction, and which is highly eflicient and etfective in operation.

With the above and related objects in view, this invention consists of the details of construction and combination of parts as will be more "fully understood from the following detailed description when read in conjunction with the accompanying drawing, in which:

FIGURE 1 is a plan view of a corrugated paperboard blank from which an expansible carton embodying this invention is formed.

FIGURE 2 is a perspective view of the blank in partly folded position with marginal edges of the side flaps in overlying sealed relationship so as to form the front panel of the carton.

FIGURE 3 is a fragmentary perspective view of the bottom portion of the expansible carton with the bottom flap sealed in overlying relationship with the lower portion of the front panel.

, FIGURE 4 is a perspective view of the carton in fully expanded position with the top flap open preparatory to sealing thereof.

FIGURE 5 is a fragmentary perspective view of the lower portion of the expanded carton taken generally along lines 5-5 of FIGURE 4.

Referring now in greater detail to the drawing in which similar reference characters refer to similar parts, I show a corrugated paperboard single blank, in FIGURE 1, which is so shaped and scored as to provide, when folded and adhesively secured, an expansible .gusset carton that resembles an envelope in flat condition but which is adapted to be expandedly formed into box-like configuration. The blank is preferably [fabricated from singletaced, corrugated paperboard of a special design, generally classified in the trade as B-fluting.

The blank configuration comprises a generally rectangular central panel 10 having a pair of inwardly folding lateral panel sections 12 outwardly extending therefrom along longitudinal scores 13. A second pair of folding panel sections .14 are secured to the tfirst panel sections along intermediate fold lines 15. Extending outwardly from the second folding panel sections on longitudinal scores 17 are respective win-g sections 16 and 18 which are adapted to overlap at their marginal edges when the blank is folded inwardly, outwardly, and then inwardly along the triple score lines 16, 15, and 17. A paste or gum is applied to the portion -19 so that when the overlapped edges of the wing sections 16 and 18 are pressed together they are adhesively secured and form a center seam front panel 20 which overlies the central or back panel 10.

A top closure 30 upwardly extends from the central panel 10 along transverse scores 21 and includes a sealing flap 32 together with intermediate sections 34 and 36 dis posed between transverse creases 33 and 35. Hinged to the lower edge of the central panel 10 is a bottom panel 40 which includes a pair of foldable panel sections 42 and 44 as well as a sealing flap 46. The bottom panel sections 42 and 44 and the sealing flap 46 are hinged together along triple transverse scores 45, 47, and 49.

Downwardly depending from the lateral panel sections 12 and 14 and contained intermediate continuations of the transverse scores 45 and 47 are a pair of gusset portions 51) and 52. These gusset portions 50 and 52 have respective diagonal scores 51 and 53 along which these portions are adapted to break to form triangular corner gussets during expansion of the carton. A sealing tab 58 depends from each gusset portion 50 along score line 47 and is hinged to the lateral edges of bottom panel section 44 along extensions of the longitudinal scores 13.

Upper corner closures are defined by corner flaps 62 and 64 which upwardly extend from the respective lateral panel sections 12 and 14 along score line 21, both corner flaps terminating along a line registering with transverse score 33 and being hinged to each other along continuations of longitudinal scores 15. The corner flap portions 62 are split or spaced from the top panel sections 34 and 36 along extensions of the longitudinal scores 13. A transverse score 65 registering with score 35 divides the flaps 62 and 64 into sections along which the corner closures may break when the carton is partially expanded.

The blank is formed into the expansible carton by folding the wing portions inwardly, outwardly and inwardly along the longitudinal scores 13, 15, and 17 so as to bring the lateral panel sections 12 and 14 into interiorly folded overlying disposition. The wings 16 and 18 are overlapped at their marginal edges and secured by adhesive at 19 so as to define a front panel 20 with a center seam. This initial folding operation causes the gusset portions 50 and 52 to be into face to face contact with each other while the sealing tabs 58 overlie the outboard areas of the bottom panel section 44. Similarly, the corner flaps 62. and 64 are urged into facing contact. FIG- URE 2 is generally illustrative of the preliminary configuration of the carton after the first steps, as set forth above, have been completed. It is also to be observed that the outer marginal edge of the corrugated face of the wing 16 may be adhered to the abutting smooth-back face of the wing 18.

The corrugated flutes on both the top sealing flap 32 and the bottom sealing flap 46 are pressed flat by passing them through steel rollers, for example. Similarly, the corrugated face of each gusset portion 52 is pressed flat so that better adhesive attachment will be provided when these surfaces are glued to the respective faces which they will abut. In addition, the fold line 47 is re-scored preparatory to the bottom flap fold-over and seal.

Glue is now applied to the flattened corrugated face of the bottom flap 46 and also to the now upwardly facing smooth surface of the sealing tab 58. If desired, the corrugated surface of the now upwardly facing gusset portions 52 may have adhesive applied thereto additionally. Lastly, a pressure sensitive adhesive is applied to the flattened corrugated surface of the top sealing flap 32 and also to the upper margin of the smooth, now outwardly facing surface of the front panel 20.

The bottom panel 40 is now folded outwardly along the intermediate score line 47 so that the corrugated face of the bottom sealing flap 46 is adhesively secured into face-to-face contact with the lower margin of the front panel 20. The smooth surface of the sealing tabs 58 will accordingly be pressed against and sealed in contact with the corrugated face of the corresponding gusset portions 52. As is apparent, the bottom corners of the carton are now fully closed and sealed, susbtantially as shown in FIGURE 3.

When the flat envelope, shown in FIGURE 3, is to be expanded to form the boxlike container of FIGURE 4, the front panel 20 is moved outwardly away from the back panel 10. The panel sections 12 and 14 hinge outwardly along the lines of fold 13, 15, and 17 respectively and form side walls 70 and 8t Simultaneously the trans verse scores 45 and 49 break into folds while the bottom panel sections 42 and 44 are urged into a common plane to define the bottom wall 40, as shown in FIGURES 4 and 5. During this expansion, the gusset portions 50 and 52 break along the diagonal folds 51 and 53 so that a triangular gusset is formed which lies in a plane parallel to and in abutment with thebottom panel 46. The upper corner flaps 62 and 64 fold open in unison with the lateral panel sections 12 and 14 and form common planes with the side walls 70 and 80. However, when the top flap 30 is folded downwardly so that its sealing flap 32 abuts the front panel 20, the corner flaps 62 and 64 are flattened along the fold line 21 so' as to underlie the top panel 30. These cornerflaps not only protect the contens of the container at its upper lateral edges but also serve to reinforce the top corners thereof against crushing. In a similar manner, the triangular gussets 50 and 52 reinforce the bottom corners of said carton. When the carton is shipped as a flat envelope, the corner flaps 62 and 64 may be folded along the intermediate score 65. This will also allow perfect registration of the pressure sensitive glue on flap 32 and upper portion of front panel 20.

The corrugated paperboard used in the fabrication of the carton hereindescribed serves to isolate fragile articles contained therein against shock, vibration and atmospheric conditions. The carton itself is easily formed on conventional continuous gumming and folding machines. In view of the nature of the resiliently expansible panels, the carton tends to maintain itself in collapsed position. Thus, when the contents are not sufficient to fully expand the carton into boxlike configuration, the various panels tend to resiliently bear upon the contained articles and retain them in a generally stable position therein. Many different articles including books, papers, and even glassware, such as bottles and dishes, can be conveniently handled by the above expansible carton. A single carton size can elficiently accommodate objects of various shapes and cubic dimensions. It is therefore obvious that the instant carton can be employed as a flat protective envelope, as a boxlike shipping container, or even as an intermediate collapsible container which would space adjacent articles in a case from each other.

Although this invention has been described in considerable detail, such description is intended as being illustrative rather than limiting since the invention may be variously embodied, and the scope of the invention is to be determined as claimed.

What is claimed is:

A method for fabricating an expansible carton from single-faced, fluted corrugated paperboard comprising the steps of:

(a) simultaneously scoring the smooth face of the paperboard and at the same time cutting the paperboard to form a one-piece blank having the following configuration: a rectangular back panel, top and bottom panels integrally connected to the respective upper and lower edges of said back panel along transverse triple scored fold lines, a pair of rectangular wings at the respective lateral edges of said back panel along longitudinal triple scored fold lines, a diagonally-scored gusset portion depending from each panel section intermediate the longitudinally scored fold lines and downwardly projecting to the line co-extensive with the medial transverse fold line at the lower edge of said back panel whereby the diagonal scores of adjacent gusset portions define a V, a sealing tab depending from each of the interiormost gusset portions only along the medial transverse fold line and projecting downwardly to the line co-extensive with the lowermost of the transverse fold lines, and a pair of corner flaps upwardly extending from the panel sections, which are intermediate the longitudinal fold lines, from a line coextensive with the upper edge of the back panel to the line co-extensive with the uppermost transverse fold line and including an intermediate score line co-extensive with the medial transverse fold line thereat,

(b) folding the wings inwardly, outwardly and then inwardly along the triple longitudinal fold lines respectively so that the marginal edges of the wings overlap and whereby the adjacent panel sections, the adjacent gusset portions and the adjacent corner flaps overlie one another in face-to-face abutting rela tionship,

(c) sealing the overlapped edges of the wings to de- 7 fine a front panel with a central seam in overlying disposition with the back panel,

(d) pressing that the corrugated flutes on the portions of the top and bottom panels extending outwardly from the respective distal transverse fold lines to define top and bottom sealing flaps,

(e) applying adhesive to the flattened corrugated flutes of the top and bottom sealing flaps as well as to the corrugated flutes of the now upwardly-facing sealing tabs,

(f) folding the bottom panel upwardly along the corresponding medial transverse fold line so that the bottom sealing flap is adhesively secured to the lower portion of the front panel and the sealing tabs are adhesively secured to the faces of the adjacent exterior gusset portions to define a flat, envelope-like container which is adapted to be expanded into boX- like configuration,

(g) expanding the adjacent overlying lateral panel sections along the longitudinal fold lines until the adjacent lateral panel sections define a plane and causing the overlying adjacent bottom panel sections to define a plane simultaneously therewith whereby the respective gusset portions will break along their respective diagonal fold lines to form triangular sections underlying the now flat planar bottom panel sections,

(h) folding the corner flaps inwardly into a common plane perpendicular to the planes of the lateral panel sections, and

(i) sealing the top sealing flap into contact with the upper portion of the front panel so as to form an upper closure for the carton in both collapsed envelope disposition and in expanded box-like disposition.

References Cited by the Examiner UNITED STATES PATENTS 1,936,136 11/1933 Lindgren 9336 2,782,977 2/1957 Thompson. 2,899,874 8/1959 Normandin 93-35 XR BERNARD STICKNEY, Primary Examiner. 

